Polymer compositions

ABSTRACT

A composition having improved processability is provided comprising from 92 to 99% by weight of a thermoplastic polymer containing 66.7% to 95% molar of acrylonitrile (calculated independently of any diene rubber which may be present) and 8% to 1% by weight of at least one processing aid selected from sulphones.

United States Patent Nield Dec. 30, 1975 POLYMER COMPOSITIONS [56] References Cited [75] Inventor: Eric Nield, Watton-at-Stone, TED TATE PA England 2,811,505 10 1957 Schulken 260/308 R [73] Assignee: Imperial Chemical Industries 2 Easdekls g '2 g L'mited London En land 1 es l 5 g 3,654,323 4/1972 Clark 260/308 R 22 Filed: Apr. 30, 1974 Appl. No.: 465,556

Related U.S. Application Data Continuation-impart of Ser. No. 357,573, May 7, 1973, abandoned, which is a continuation-in-part of Ser. No. 207,975, Dec. 14, 1971, abandoned, which is a continuation-in-part of Ser. No. 118,191, Feb. 23, 1971, abandoned.

FOREIGN PATENTS OR APPLICATIONS 1,143,408 2/1969 United Kingdom Primary Examiner-Paul R. MichI Attorney, Agent, or Firm-Cushman, Darby & Cushman ABSTRACT A composition having improved processability is provided comprising from 92 to 99% by weight of a thermoplastic polymer containing 66.7% to 95% molar of 4 acrylonitrile (calculated independently of any diene rubber which may be present) and 8% to 1% by weight of at least one processing aid selected from sulphones.

. 14 Claims, No Drawings POLYMER COMPOSITIONS abandoned.

This application relates to polymeric materials containing a high proportion of acrylonitrile and in particular to compositions having improved processability.

Copolymers containing a high proportion of acrylonitrile including those containing aromatic olefine, those toughened by blending with compatible graft .copolymers and graft copolymers having a superstrate of the acrylonitrile copolymer, may be injection moulded to produce articles having high impact strength but the impact strength measured on samples taken across the direction of flow may be lower than that measured on samples taken along the line of flow due to alignment of the molecules during moulding. The problem is more acute with polymeric materials containing a high proportion of acrylonitrile compared with those having only low acrylonitrile content on account of higher melt viscosities which occur for similar molecular weights and moulding temperatures. We have found in general that where the copolymers require the properties to be modified by the addition of additives (for example plasticisers, or graft copolymers for toughening) additives which are conventionally used for materials containing a higher molar proportion of aromatic olefine than acrylonitrile (hereinafter referred to as ABS materials) are not suitable for use with polymers containing high proportions of acrylonitrile due to poor compatibility between the two components. Poor compatibility gives rise to poor physical properties such as lower tensile strength and lower impact strength.

1t has now been found that the flow properties of copolymers containing a high proportion of acrylonitrile may be improved by incorporating a small amount of a selected sulphone.

According to the present invention, a composition having improved processability is provided comprising I from 92 to 99% by weight of a thermoplastic polymer from sulphones which have the general formula R-so.,-R'

where R and R are selected from the group consisting of aromatic radicals, the processing aid'being a liquid at the temperature employed during the processing.

The thermoplastic polymer used in the compositions of the invention may be:

2 4. a homogeneous copolymer of acrylonitrile blended with a compatible graft copolymer; 5. a superstrate of a graft copolymer having a diene rubber substrate blended with a compatible resin; 6. a copolymer of acrylonitrile blended with a compatible graft copolymer. Polymers containing more than 95% molar of acrylonitrile, are excluded because they are not generally thermoplastic but have to be fabricated from solution rather than by thermoplastic melt-processing.

Homogeneous copolymers may be made by any suitable means such as for example those described in British Patent Specifications Nos. 663,268 and 1,185,305. The homogeneous copolymer, however, becomes increasingly difficult to melt-process as the molar concentration of acrylonitrile increases, particularly when the concentration exceeds 85%. However, progressively reducing the acrylonitrile content results in reduced strength, stiffness, impermeability and resistance to chemical attack so that to obtain the optimum values for such properties it is preferable that the acrylonitrile content be at least 75% molar. Compositions according to the present invention provide more facile melt forming whilst not impairing the desirable physical 1. a homogeneous copolymer comprising of acryloniproperties of the resultant product. For ease of moulding, it is also preferably to control the molecular weight of the homogeneous copolymer such that the reduced viscosity of the copolymer (measured on a solution of 0.5 g of copolymer in 100 cm of dimethyl formamide at 25C) lies between 0.5 and 1.2 when the acrylonitrile content is less than molar and lies between 0.5 and 1.8 when the acrylonitrile concentration is 80% molar or more.

The impact strength of such homogeneous copolymers may be improved by blending with a compatible graft copolymers, and such a blend is therefore often preferred as a moulding material. Where a graft copolymeris blended with the resin copolymer, the two must be compatible. In order to obtain compatibility, the molar proportion of acrylonitrile in the graft copolymer I should be approximately the same as the molar proportion of acrylonitrile in the resin copolymer. However, thc'proportions of acrylonitrile in.the two components may differ by about 10 mole without unduly affecting the compatibility. Grafts containing a diene rubber-substrate such as polybutadiene and a superstrate which isa copolymer of acrylonitrile and at least one ethylenically unsaturated monomer such as acrylonitrile/isobutene copolymer or an acrylonitrile/ acrylic or methacrylic ester copolymer (for example as described in British Patent Specification. No. 1,143,408) or grafts having a superstrate of a.homogeneous acrylonitrile/styrene copolymer (for example as described in British Patent Specification No. 1,185,306) are very suitable. The toughness of the final blended composition is given not only by the amount of rubber it contains (preferably 1% to 50% by weight) but also by the proportion of superstrate in the graft copolymer used for blending. In general, the desirable physical properties such as hardness, gloss, resistance to chemical attack and softening point, of polymeric resins containing a high proportion of acrylonitrile, are adversely effected to a minimum degree when the proportion of superstrate in the graft copolymer is at a minimum. However, there must be sufficient super- 1 strate to provide compatibility between the 'graft and the resin. While graft copolymers may be used in which the substrate represents from 10% to by weight of 3 the graft copolymer, those containing at least 70% by weight of substrate are generally convenient.

-The processing aid may be any sulphone of the general formulae described hereinbefore, or it may be a mixture of two or more of such sulphone-s, which is a liquid at the temperature employed during the moulding process. For shaping the copolymers, temperatures of at least 150C are normally required, and it is preferred to avoid temperatures greater than 300C since thermal degradation may occur rapidly at such high temperatures. The most suitable temperature, however, will depend on the particular copolymer selected. Suitable sulphones include diphenyl sulphone and bis- (4-chlorophenyl) sulphone.

Incorporation of from 1 to 8% by weight of the present processing aids reduces the melt viscosity of the polymeric material, resulting in a more even distribution of physical properties in an injection-moulded article. Thus the notched impact strength measured across the line of flow is increased and may be as high as the value measured along the line of flow. However, the Vicat softening point may be reduced as the quantity of processing aid is increased, and compositions containing about 4 to 8% by weight of processing aid are particularly preferred.

The processing aid may be incorporated in the composition at-any stage of its preparation. Where the polymeric material comprises a blend of a resin copolymer and a graft copolymer formed by blending the latices of the two copolymers, the processing aid may very conveniently be added during the blending stage. It may, however, be added to the polymerisation mixture during the course of the preparation of the resin copolymer. Alternatively, the processing aid may be added to the polymer composition by means of meltblending either using an extruder or using hot rolls.

Compositions according to the invention may be mixed with any desired fillers, stabilisers and other additives. Compositions of the present invention may be fabricated by any method available to the processing ofv thermoplastic materials. The compositions can therefore be compression-moulded; blow-moulded; extruded; calendered and cast into films; moulded into plaques, bottles and other articles.

In the following examples, the notched impact test was carried out at room temperature (about 20C). A specimen 50 mm long, 6 mm wide and 3 mm thick was given a 45 notch 2.5 mm deep (tip radius 025 mm) in the centre of one edge. 1t was supported between two supports 38 mm apart and struck centrally on the edge opposite the notch by a pendulum dropping from 30 cm with more than sufficient energy to break the speci- 4 men. From the residual energy of the pendulum, the energy required to break the specimen was calculated and divided by the cross-sectional area of the specimen at the notch. The resulting value represents the energy required to break the material.

The unnotched impact strength was measured on a specimen 9 mm wide and 3 mm thick resting horizontally (with the narrow face uppermost) against two supports 38 mm apart. The specimen was struck centrally on the wide face by a horizontally moving pendulum falling from 305 mm, with normally sufficient energy to break the specimen. From the residual energy of the pendulum, the energy required to break the specimen was calculated and then divided by the crosssectional area of the specimen. The resulting value (expressed in kJ/m represents the energy required to cause cracks and break the material.

The modulus was measured as the tensile creep modulus at 100 seconds and 0.2% strain.

Permeability was measured according to the pressure differential method of N T Notley which is described in Journal of Applied Chemistry 1963, volume 13, page 107. The measurements were made using essentially dry gases at 30C using a pressure differential of 1 atmosphere.

The following examples illustrate the invention; parts and percentages are by weight.

EXAMPLE 1 A copolymer blend A was prepared by latex blending a graft copolymer comprising a substrate of polybutadiene (about and a superstrate (about 50%) of a homogeneous acrylonitrile/styrene copolymer (molar ratio 3:1 and a resin comprising a homogeneous acrylonitrile/styrene copolymer (molar ratio 3: 1) in such proportions that the blend contained 10% polybutadiene. The blend was stabilised with 1% of 2,6-di-tbutyl-4-methylphenol and 0.5% of dilauryl thiodipropionate. The copolymer blend parts) was mixed in a Banbury mixer (chart temperature C) with a series of additives indentified in Table 1 below, some difficulty being experienced with additive C. After mixing, the composition was milled, the front roll having a temperature of l30-135C, and the crepe was cut and diced in a Masson cutter. The melt viscosity of each composition was measured at a rate of l000/sec and'temperature of 260C except where indicated, and the colour recorded after 10 minutes at 260C. When the samples set up, (i.e. the viscosity of the molten polymer rose sharply), the time which elapsed before the onset of setting up was also measured, and is identified in Table 1 as the set up time.

Table 1 Additive C his-(4-chlorophenyl) 5 sulphone D (diphenyl sulphone (tristcaryl citrate F. tristearyl citrate Nonc diphenyl sulphone 5 Quantity of additive parts by weight Colour 10 minutes) Melt viscosity (Nsm Set up time minutes 5 6 The mechanical properties of compression-moulded 1000/sec) and the results of physical testing on samples samples of the compositions were measured and are compression-moulded at 260C are shown in Table 4. given in Table 2.

Table 2 Table 4 Additive Notched lmpact Modulus Vicat softening strength k.l/m GN/m" point "C Melt VISCOSlly (Nsm Notched one-tenth full Modulus impact Composi- 180C 220C 260C GN/m strength A 10.6 3.1 103.4 109.4 tion kJ/m' B 12.7 3.2 93.6 102.8 C 7,4 3, 9 10546 K 22 7.6 4.0 3.0 18.8 D 11.9 3.1 960 1 102.0 L 5.3 2.9 3.1 21.2 F. 11.2 2.9 102.6 110.4

The notched impact strengths of the compositions were also measured on samples injection-moulded at These YQSUItSShOW that p y sulphone re duces 200 or 230 Samples f test were taken along or the melt viscosity at all melt temperatures within the across the direction of flow range normally used for melt processing.

The results are given in Table The same blend (.1) (100 parts) was compounded with 5 parts of d1phenyl sulphone using a Banbury T bl 3 mixer (chart temperature 115C), milled (front roll 6 temperature l-30'l35C), Masson-cut and finally in- Nolchcd impact Strength jection-moulded into 1 14 mm diameter, 3.2 mm thick Addi- 200C 230C tive along flow across 110w along flow across How i The notched Impact SFFengths of the moulded dlscs of the resultant compos1t1on (M) were measured a for samples talgen both along and across the direction C 11:11 2.5 12.3 1.9 of flow, and the values obtained are compared with those for the blend (J) containing no diphenyl sul- 1-. 15.1 8.4 15.9 8.4

phone, the results bemg given in Table 5.

Table 5 Moulding conditions Notched impact strength (kl/m") Temperature 205C 0C 2( C along across along across along across Composition .1

200 19.2 12.1 230 15.3 12.8 8.3 6.3 6.3 3.4 Composition M EXAMPLE 2 EXAMPLE 3 The following compositions were made by adding various quantities of bis-(4-chlorophenyl) sulphone to Two compositions were prepared by compounding 1500 g of a blend (N) which consisted of a resin com- 9725 g 11 blend (-1) Containing 10% polyb tadien in prising a homogeneous acrylonitrile/styrene resin conthe form of a graft copolymer comprising about 50% minin 22.3 mole styrene, a graft copolymer compolybutadicne u strat and ryl ni ril yr n prising about 50% of a substrate of polybutadiene and (molar r1100 3Z1 supcrstrflte 11nd a homogeneous correspondingly about 50% of a superstrate of a homoucrylonitrile/styrene resin Containing 3 mole geneous acrylonitrile/styrcne copolymer (molar ratio y with additive and with 486-25 g of 3:1 the amount of graft polymer beingsuch that blend diphenyl sulphone. The compositions were made in a (N) contained 10% polybutadiene; blend (N) also con- 38 mm Bone extruder ha ing a vented barrel, and tained 2%01 tristearyl citrate. The materials were commm die. In the preparation of composition L, the blend pounded on a B b mixer l5()C), ill d and the sulphone were first mixed in a Henschel mixer (at C) and Masson-cut. The compositions proand then in the Bone extruder. In both cases the reduced were divided, part being compression-moulded corded barrel temperatur s 01' th CXtrud r were at 200C for 5 minutes while the remainder were injec- |65/300/308/190/180C here the temper re 65 tion-moulded at temperatures of200Cand 230C.The 180C represents the die temperatures. The screw mechanical properties of the mouldings are given in speed in each case was 50 rpm. The melt viscosities at T bl 6 for com ression mouldings and Table 7 for 180C. 220C and 260C (measured at a rate of injection mouldings.

Table 6 Composhis-(4- Vicat Melt modulus Notched ition chlorophenyl Softening vis- GN/m impact sulphone point "C cosity strength g wt 71 onefull (Nsm' kJ/m" tenth N 0 99.0 110.2 5.3 3.1 15.0 0 30 2 102 108 4.7 3.2 19.8 P 60 4 100.4 105.6 4.2 3.1 21.4 0 9O 6 90.0 102.2 4.3 3.2 21.2 R 120 8 94.6 101.8 4.0 3.2 17.7 S I50 94.4 99.8 3.5 3.3 20.6

Table 7 by weight of methyl acrylate in the presence of 8l0 parts by weight of butadiene-acrylonitrile copolymers Notched impact strength at 195C (kl/m Injection-moulded Injection-moulded contamlng dpproxlmdtely 70 percent by welght of l c 200C 23oc mer units derived from butadiene, were mixed with alng flow 110F058 flow along flow across flow diphenyl sulphone and Santicizer 11-1 and the result- N 28.4 129 ing compositions evaluated for melt viscosity (mea- 0 127 sured at 200C) and unnotched impact strength. The P 28.4 17.4 28.2 18.2 I T bl 9 h h h l I h Q 279 m3 309 res u ts( a e )s owt at 1p e ny sup one is more R 25.6 17.6 30.9 18.2 efficient in reducing melt viscoslty than Santiclzer S 25.8 18.9 24.4 18.9 1H

Table 9 EXAMPLE 4 (parts by weight per Melt Viscosity Unnotched l I Q 2 A series of homogeneous copolymers of acrylonitrile hundred Pam mm) (Nbm mpact Strengxh and styrene containing 75, 85 and 90% molar acrylonih I I 2 2-; trile were prepared by the method described in British u 'g f 'g' i mi 28 specification No. 1,185,305. Samples of the copolymers were mixed with varying amounts of diphenyl sulphone and the melt viscosity (measured at 200C) of 1 i the resumng co'mposltlom the unnotched impact 1. A composition having improved processability strength of i P moulded from the composmofl comprising from 92 to 99% by weight of athermoplasa P a y of films p p from e compost tic polymer containing 66.7% to 95% molar of units of tron determined. The results are presented in Table 8. acrylonitrile which is a copolymer and/Or a superstmte of a graft copolymer having a diene rubber substrate,

Table 8 Acrylon 'Diphenyl Melt Unnotched Permeability itrile sulphone viscosity impact mole rns N molar) (parts by (Nsm"-) strength weight per k.I/m 02 CO2 hundred parts copolymer) 75 0 710 14.1 5 510 15.4 10 400 14.6 15 290 12.6 0 960 20.7 2.()Xl0"" 1.9X1()"" 5 620 21.2 1.5 1o-'" 2.sx10-'" 10 450 13.8 0 1900 17.9 4.1 10-' l0-l9 5 650 4.2 3.1 1o-' 10-19 10 510 18.1

The results given in Table 8 show that (l) melt visthe amount of acrylonitrile present being calculated cosity rises with acrylonitrile content; (2) melt viscosity independently of any diene rubber which may be presdecreases with increasing diphenyl sulphone concenem, and 8% to 1% by weight of at least one processing tration substantially without detriment to unnotched aid selected from the group consisting of diphenyl sulimpact strength and with marginal improvement in phone and bis-(4-chlorophenyl) sulphone, the processoxygen impermeability and (3) impermeability im- 60 ing aid being a liquid at the temperature employed proves with increasing acrylonitrile content. during the processing. 2. A com osition accordin to claim I in which the EXAMPLE 5 H g thermoplastic polymer is a homogeneous copolymer Samples of Barex" 210 (Barex" is a registered comprising 66.7% to molar of units from acryloni- Trade Mark) which is a nitrile rubber modified 65 trile and 33.3% to 5% molar of units from at least one acrylonitrile-m ethyl acrylate copolymer consisting of copolymer produced by the graft copolymerisation of 73-77 parts by weight of acrylonitrile and 23-27 parts aromatic olefine.

3. A composition according to claim 1 in which the thermoplastic polymer is a copolymer of acrylonitrile with at least one ethylenically unsaturated monomer copolymerisable therewith.

4. A composition according to claim 1 in which the thermoplastic polymer is a superstrate of a graft copolymer having a dienc rubber substrate.

5. A composition according to claim 1 in which the thermoplastic polymer is a homogeneous copolymer of acrylonitrile blended with a compatible graft copolymer having a diene rubber substrate and a superstrate containing acrylonitrile (45 to 90% molar) the amount of dienc rubbcr in the blend being 1 to 50% by weight.

6. A composition according to claim 1 in which the thermoplastic polymer is a superstrate of a graft copolymer having a dienc rubber substrate blcnded with a compatible resin containing acrylonitrile (66.7 to 95% molar), the amount of diene rubber in the blend being l to 50% by weight.

7. A composition according to claim 1 in which the thermoplastic polymer is a copolymer of acrylonitrile blended with a compatible graft copolymer having a 10 diene rubber substrate and a superstrate containing acrylonitrile (45 to molar) the amount of diene rubber in the blend being I to 50% by weight.

8. A composition according to claim 1 in which any aromatic olefine present is styrene and/or alpha-methyl styrene.

9. A composition according to claim 1 in which the processing aid is present in concentration 4 to 8% by weight.

10. A composition according to claim 1 in which the processing aid is diphenyl sulphone.

11. A composition according to claim I in which the processing aid is bis-(4-chlorophenyl) sulphone.

12. A composition according to claim 1 in the form of a molded article.

13. A composition according to claim 12 in which the molded article is a bottle.

14. A composition according to claim I in the form of a film. 

1. A COMPOSITION HAVING IMPROVED PROCESSABILITY COMPRISING FROM 92 TO 9990 BY WEIGHT OF A THERMOPLASTIC POLYMER CONTAINING 66.7% TO 95% MOLAR UNITS OF ACRYLONITRILE WHICH IS A COPOLYMER AND/OR A SUPERSTRATE OF A GRAFT COPOLYMER HAVING A DIENE RUBBER SUBSTRATE THE AMOUNT OF ACRYLONITRILE PRESENT BEING CALCULATED INDEPENDENTLY OF ANY DIENE RUBBER WHICH MAY BE PRESENT, AND 8% TO 1% BY WEIGHT OF AT LAST ONE PROCESSING AID SELECTED FROM THE GROUP CONSISTING OF DIPHENYL SULPHONE AND BIS-(4-CHLOROPHENYL) SULPHONE, THE PROCESSING AID BEING A LIQUID AT THE TEMPERATURE EMPLOYED DURING THE PROCESSING.
 2. A composition according to claim 1 in which the thermoplastic polymer is a homogeneous copolymer comprising 66.7% to 95% molar of units from acrylonitrile and 33.3% to 5% molar of units from at least one aromatic olefine.
 3. A composition according to claim 1 in which the thermoplastic polymer is a copolymer of acrylonitrile with at least one ethylenically unsaturated monomer copolymerisable therewith.
 4. A composition according to claim 1 in which the thermoplastic polymer is a superstrate of a graft copolymer having a diene rubber substrate.
 5. A composition according to claim 1 in which the thermoplastic polymer is a homogeneous copolymer of acrylonitrile blended with a compatible graft copolymer having a diene rubber substrate and a superstrate containing acrylonitrile (45 to 90% molar) the amount of diene rubber in the blend being 1 to 50% by weight.
 6. A composition according to claim 1 in which the thermoplastic polymer is a superstrate of a graft copolymer having a diene rubber substrate blended with a compatible resin containing acrylonitrile (66.7 to 95% molar), the amount of diene rubber in the blend being 1 to 50% by weight.
 7. A composition according to claim 1 in which the thermoplastic polymer is a copolymer of acrylonitrile blended with a compatible graft copolymer having a diene rubber substrate and a superstrate containing acrylonitrile (45 to 90% molar) the amount of diene rubber in the blend being 1 to 50% by weight.
 8. A composition according to claim 1 in which any aromatic olefine present is styrene and/or alpha-methyl styrene.
 9. A composition according to claim 1 in which the processing aid is present in concentration 4 to 8% by weight.
 10. A composition according to claim 1 in which the processing aid is diphenyl sulphone.
 11. A composition according to claim 1 in which the processing aid is bis-(4-chlorophenyl) sulphone.
 12. A composition according to claim 1 in the form of a molded article.
 13. A composition according to claim 12 in which the molded article is a bottle.
 14. A composition according to claim 1 in the form of a film. 